U.S. patent number 6,834,677 [Application Number 10/136,899] was granted by the patent office on 2004-12-28 for over-molded check valves for fluid delivery systems.
This patent grant is currently assigned to Hewlett-Packard Development Company, L.P.. Invention is credited to Louis C. Barinaga, Daniel D. Dowell.
United States Patent |
6,834,677 |
Barinaga , et al. |
December 28, 2004 |
**Please see images for:
( Certificate of Correction ) ** |
Over-molded check valves for fluid delivery systems
Abstract
An over-molded fluid control value for use in fluid delivery
systems. An embodiment of the fluid control valve includes a rigid
substrate having a opening defined therein, and a valve structure
fabricated of an elastomeric material. The valve structure is
over-molded over at least a portion of the rigid substrate and
including a valve portion extending over the opening, the valve
portion movable in response to a differential fluid pressure to
allow fluid flow.
Inventors: |
Barinaga; Louis C. (Salem,
OR), Dowell; Daniel D. (Albany, OR) |
Assignee: |
Hewlett-Packard Development
Company, L.P. (Houston, TX)
|
Family
ID: |
29249693 |
Appl.
No.: |
10/136,899 |
Filed: |
April 30, 2002 |
Current U.S.
Class: |
137/846;
137/512.1; 137/844; 251/368 |
Current CPC
Class: |
F16K
15/147 (20130101); Y10T 137/788 (20150401); Y10T
137/7839 (20150401); Y10T 137/7882 (20150401) |
Current International
Class: |
F16K
15/14 (20060101); F16K 015/14 () |
Field of
Search: |
;137/843,844,845,846,512,512.1,512.15,375,852,859 ;251/331,368
;347/85,86,87 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Krishnamurthy; Ramesh
Claims
What is claimed is:
1. An over-molded fluid control valve, comprising: a rigid
substrate having an opening defined therein; a unitary valve
structure fabricated of an elastomeric material, said elastomeric
material over-molded onto arid over at feast a portion of the rigid
substrate during a molding process to define the unitary valve
structure including at least one valve portion extending over said
opening, the valve portion normally closed to prevent fluid flow,
the valve portion movable in response to a differential fluid
pressure to allow fluid flow, wherein said valve structure includes
a tapered duckbill portion having a slit formed at a distal end,
and wherein the slit is normally closed against fluid flow, said
slit opening in response to said differential fluid pressure, and
wherein the rigid substrate has first and second opposed surfaces,
and first end second layers of said elastomeric material are
over-molded over said first and second opposed surfaces.
2. The valve of claim 1, wherein the first and second opposed
layers are joined through the opening.
3. The valve of claim 1, wherein the elastomeric material is EPDM
or a thermoplastic elastomer.
4. The valve of claim 1, wherein said differential pressure exceeds
a break pressure of said valve.
5. A host part having a boss formed therein about a fluid port,
further comprising a fluid control valve disposed in said fluid
port to control fluid flow through said fluid port, said fluid
control valve comprising an over-molded fluid control valve,
comprising: a rigid substrate having a opening defined therein: a
valve structure fabricated of an elastomeric material, said valve
structure over-molded over at least a portion of the rigid
substrate and including at least one valve portion extending over
said opening, the valve portion normally closed to prevent fluid
flow, the valve portion movable in response to a differential fluid
pressure to allow fluid flow.
6. An over-molded fluid control valve, comprising: a rigid
substrate having a opening defined therein: a unitary valve
structure fabricated of an elastomeric material, said elastomeric
material over-molded onto and over at least a portion of the rigid
substrate during a molding process to define the unitary valve
structure and including at least one valve portion extending
oversaid opening, the valve portion normally closed to prevent
fluid flow, the valve portion movable in response to a differential
fluid pressure to allow fluid flow, wherein said valve portion
comprises a membrane portion which extends over said opening, and
said membrane includes a web portion which resiliently moves in
response to said differential pressure and a disk portion of
increased thickness; and a valve seat structure against which said
disk portion seals in the absence of the differential pressure,
preventing fluid flow, wherein said valve seat structure includes a
seat member defining a half-toroidal shape.
7. An over-molded fluid control valve, comprising: a rigid
substrate having a opening defined therein; a unitary valve
structure fabricated of an elastomeric material, said elastomeric
material over-molded onto and over at least a portion of the rigid
substrate during a molding process to define the unitary valve
structure including at least one valve portion extending over said
opening, the valve portion normally closed to prevent fluid flow,
the valve portion movable in response to a differential fluid
pressure to allow fluid flow, further comprising a gland seal
disposed about an outer peripheral surface of said rigid
substrate.
8. The valve of claim 7, wherein the gland seal is a unitary
over-molded structure formed with said valve portion of said
elastomeric material.
9. A fluid control assembly, comprising: a host part having a fluid
port and a circumferential boss; an over-molded fluid control valve
disposed in said circumferential boss to control fluid flow through
said fluid port, the valve comprising: a rigid substrate having a
opening defined therein; a valve structure fabricated of an
elastomeric material, said valve structure over-molded over at
least a portion of the rigid substrate and including at least one
valve portion extending over said opening and normally preventing
fluid flow, the valve portion movable in response to a differential
fluid pressure to allow fluid flow.
10. The assembly of claim 9, further including a gland seal formed
of said elastomeric material about a periphery of said rigid
substrate to sealingly engage an inner surface of said
circumferential boss.
11. The assembly of claim 9, wherein said gland seal forms a
unitary over-molded structure with said valve portion.
12. The assembly of claim 9, wherein said valve structure includes
a tapered duckbill portion having a slit formed at a distal end,
and wherein the slit is normally closed against fluid flow, said
silt opening in response to said differential fluid pressure.
13. An over-molded disk valve for fluid flow control, comprising: a
rigid substrate having a opening defined therein; a valve seat
structure defining a valve seal, the valve seat structure disposed
in or adjacent the opening; a valve structure fabricated of an
elastomeric material, said valve structure over-molded over at
least a portion of the rigid substrate and including a membrane
portion extending over said opening, the membrane portion normally
in sealing contact against said valve seal, the membrane portion
movable in response to a differential fluid pressure to allow fluid
flow.
14. The disk valve of claim 13, wherein said valve seat structure
includes a fluid conduit having a fluid port circumscribed by said
valve seal, the fluid portion normally closed by said membrane
portion in the absence of said differential pressure.
15. The disk valve of claim 14, wherein the membrane portion
includes one or more openings formed therein, and wherein fluid
flows through said one or more openings when said membrane portion
is moved to open said fluid portion by said differential
pressure.
16. A ganged set of fluid control valves, comprising: a rigid
substrate having a plurality of openings defined therein: a valve
structure fabricated of an elastomeric material, said valve
structure over-molded over at least a portion of the rigid
substrate and including at least one valve portion extending over
each of said plurality of openings, each valve portion normally
closed to prevent fluid flow, the valve portion movable in response
to a differential fluid pressure to allow fluid flow.
17. The set of claim 16, wherein each said valve portion includes a
tapered duckbill portion having a slit formed at a distal end, and
wherein the slit is normally closed against fluid flow, said slit
opening In response to said differential fluid pressure.
18. The set of claim 17, wherein the rigid substrate has first and
second opposed surfaces, and first and second layers of said
elastomeric material are over-molded over said first and second
opposed surfaces.
19. The set of claim 18, wherein the first and second opposed
layers are joined through each of said plurality of openings.
20. The set of claim 16, wherein the elastomeric material is EPDM
or a thermoplastic elastomer.
Description
BACKGROUND OF THE DISCLOSURE
A check valve is a valve that allows fluid to flow in one direction
and prevents flow in the opposite direction. Check valves are
common in industry. For example, the medical industry incorporates
check valves in many devices used for the delivery of fluid
medications.
Previous check valve designs have used mechanical attachment
techniques to create a seal between the valve body and the host
parts. These techniques consist of a mechanical joint between two
parts that squish the valve between them, creating a seal. The
joining techniques include ultrasonic welding, snap fits, adhesives
and press fits. The mechanical joining techniques require
substantial features in order to create a bond between the two
rigid parts. These features result in parts that are relatively
large and difficult to pack densely into an assembly.
A duckbill valve structure is a common design that is manufactured
in various forms. The name derives from the shape of the valve,
which is typically long and tapered. At the end of a tapered shaft,
a slit is created to allow fluid flow through the valve.
SUMMARY OF THE DISCLOSURE
An over-molded fluid control valve is disclosed for use in fluid
delivery systems. An embodiment of the fluid control valve includes
a rigid substrate having a opening defined therein, and a valve
structure fabricated of an elastomeric material. The valve
structure is over-molded over at least a portion of the rigid
substrate and including at least one valve portion extending over
the opening, the valve portion movable in response to a
differential fluid pressure to allow fluid flow.
BRIEF DESCRIPTION OF THE DRAWING
These and other features and advantages of the present invention
will become more apparent from the following detailed description
of an exemplary embodiment thereof, as illustrated in the
accompanying drawings, in which:
FIG. 1 is an isometric view of an embodiment of an over-molded
duckbill check valve structure.
FIG. 2 is an isometric cross-section taken along line 2--2 of FIG.
1.
FIG. 3 is a side view of the cross-section of FIG. 2.
FIG. 4 is an isometric view of a second embodiment of an
over-molded duckbill check valve structure.
FIG. 5 is a cross-section view taken along line 5--5 of FIG. 2.
FIG. 6 is a side cross-section view of the structure of FIG. 4
poised above a host part in which the structure is to be
assembled.
FIG. 7 is a side cross-section view, showing the check valve
structure and host part of FIG. 6 in an assembled condition.
FIG. 8 is an isometric view of an embodiment of an over-molded disk
check valve structure.
FIG. 9 is a cross-section view taken along line 9--9 of FIG. 8.
FIG. 10 is a cross-section view of an alternate embodiment of a
disk check valve structure.
FIG. 11 is a partial isometric view of a ganged check valve
structure.
FIG. 12 is a cross-section taken along line 12--12 of FIG. 11.
DETAILED DESCRIPTION OF THE DISCLOSURE
A first embodiment of an over-molded check valve is a "duckbill"
valve, shown in FIGS. 1-3 as valve structure 20, which includes an
elastomer layer 22 that is over-molded onto a rigid substrate 24.
The elastomer layer 22 is molded to form the long tapered duckbill
portion 22A, with a slit 22B formed at the distal end of the
duckbill portion. The slit can be made by a blade or lance after
the layer is formed, and can be made while the part is still in the
mold.
The rigid substrate 24 has an opening 26 formed there through. In
this embodiment, the opening 26 is circular, but other shapes can
alternatively be employed.
During the over-molding process, the elastomer layer 22 is formed
over the top surface 24A and the bottom surface 24B of the
substrate, and also over the peripheral wall 24C defining the
opening 26. Thus, the layer 22 includes an upper layer portion 22C
which is over-molded onto top substrate surface 24A, and a lower
layer portion 22D which is over-molded onto bottom substrate
surface 24B. The upper and lower layer portions are joined by a
layer portion 22E which covers the peripheral wall 24C. The upper
and lower layers serve to provide structural integrity of the
elastomer layer, with the two layers joined through the opening in
the substrate serving to hold the layers onto the substrate during
molding. Also, the layers are joined at edges of the substrate and
through the substrate openings to eliminate exposed joints between
the elastomer and substrate. This prevents ink or fluid from
penetrating between the elastomer layers and the substrate. In
other embodiments, the lower layer portion 22D may be omitted,
and/or the lateral extent of the elastomer layers abbreviated.
Exemplary materials suitable for the substrate 24 include liquid
crystal polymer (LCP), PPS and NORYL (TM). Exemplary materials
suitable for the elastomer layers include EPDM, santoprene, and
thermoplastic elastomers.
In an exemplary application, the height of the valve structure is
10 mm, a base width of 4 mm, a tip length of 3 mm, and a tip width
of 1 mm. The wall thickness of the duckbill portion is nominally
0.5 mm. The tapered portion of the duckbill portion 22A has a
height of 5 mm, and a taper angle of 30.degree.. The slit 22B is 2
mm long in this embodiment. The foregoing dimensions are by way of
illustration only; embodiments with different dimensions can be
used.
The direction of fluid flow through structure 20 is indicated by
arrow 28 (FIG. 3). A differential pressure between fluid inside the
duckbill cavity 30 and fluid on the opposite side of the valve
structure at 32 is required to allow fluid to flow in the direction
28; this differential pressure is referred to as a valve "break" or
"check" pressure. The break pressure is needed to open the slit 22B
and permit fluid flow. Fluid flow in the opposite direction is
prevented by the duckbill geometry, since positive pressure on the
exterior of the tapered duckbill portion will tend to force the
slit closed. The break pressure is affected by various factors,
including the length of the duckbill portion, the elastomer
modulus, the slit length.
The rigid substrate 24 will typically be a host part that already
exists in an assembly. This configuration allows for a minimum of
parts. Multiple valves can be molded onto an existing part,
eliminating the need for extra parts to create additional
valves.
Over-molding is a well known, two step fabrication process, in
which a rigid substrate, such as substrate 24, is first formed,
typically by injection molding. Thereafter, in a second step, a
layer of elastomer, such as layer 22, is molded onto the substrate,
typically by thermoset or thermoplastic injection molding, forming
a membrane structure.
Two over-molding methods are commonly used. The first is used for
over-molding onto rigid thermoplastics. In this process, a rigid
thermoplastic piece, is molded. A thermoplastic elastomer is then
over-molded after a section of movable coring is retracted. The
thermoplastic part may be required to endure high mold temperatures
during the second step of this process.
The second method of over-molding is used to over-mold thermoset
elastomer onto either a rigid thermoset or thermoplastic piece. In
this process, a rigid thermoplastic piece is molded using
traditional injection molding techniques. The part is then
transferred to a second mold cavity wherein the thermoset elastomer
is injected onto it. Again, the rigid piece may endure high mold
temperatures during the over-mold process.
Either of these exemplary over-molding processes, as well as other
over-molding processes, could be employed in the fabrication of the
check valve structure 20.
A second exemplary embodiment of a check valve is shown in FIGS.
4-7. This check valve structure 50 has some similarities to the
first embodiment, but is designed to be a separate part that can be
pressed onto an assembly.
The valve structure 50 includes a small rigid substrate 52, which
is partially encapsulated during the over-molding of an elastomer
portion 54 which defines the duckbill portion 54A and slit 54B, as
shown in FIG. 5. The rigid substrate 52 has a center opening 56
defined therein, through which fluid passes. The substrate 52 has
an outer circular peripheral surface 52A which includes a shoulder
52B defined by a reduction in the outer diameter of the substrate.
In other embodiments, non-circular geometries could alternatively
be employed. A gland seal geometry 54C is also molded onto the part
during the duckbill over-mold procedure. This gland seal 54C is
designed to make a fluid tight seal against the inside surface of
the boss that accepts the valve. The seal is glandular, similar to
an o-ring, and is formed about the periphery of the substrate 52 at
the shoulder 52B.
FIGS. 6-7 illustrate assembly of the duckbill check valve structure
50 into a host part 60. The part 60 includes an upstanding boss
structure 62 having an opening 64 formed there through to receive
the valve structure 50. The boss structure has a generally
cylindrical configuration, with a bevel 62A at its distal end to
facilitate insertion of the valve structure. FIG. 6 shows the
structure 50 poised above the boss 62 prior to insertion. FIG. 7
shows the structure 50 press-fitted into the opening 64, with the
gland seal 54C providing a fluid seal against the wall 62C of the
boss. The check valve structure 50 will allow fluid flow in the
direction of arrow 68 when the break pressure is exceeded, and
prevent fluid flow in the direction opposite the arrow 68.
The boss 62 can include a shoulder surface 62B to provide a stop
surface against which the valve structure 50 is seated. This can
provide an additional sealing surface for contacting the gland seal
54C. Alternatively, the shoulder surface is omitted, and the seal
is formed by the gland seal against the boss wall.
A third exemplary embodiment is an over-molded disk valve structure
80 illustrated in FIGS. 8-9. Disk valves are commonly used as check
valves. A disk valve usually includes three parts, an elastomer
disk, a host part with a rigid sealing surface, and a second host
part that compresses the disk against the sealing surface on the
first host part. This disk geometry can, in accordance with an
aspect of this invention, incorporate over-molding to reduce part
count and to minimize assembly.
The over-molded disk valve structure 80 includes a rigid substrate
82 having a through hole 84. The substrate is over-molded with an
elastomeric layer 86 defining a membrane portion 88. The membrane
portion contains a disk geometry 86A that is suspended over the
hole 82 in the substrate via a thin web 86B of elastomer. The disk
86A in this embodiment is formed by the elastomer, of a thicker
layer of the elastomer than the thickness of the web 86B.
Alternatively, the disk 86A could be formed from a rigid material,
which is over-molded by the elastomer material during the
over-molded process.
A second rigid part 90 is positioned on the inlet side of the valve
structure, and includes an upstanding boss portion 92 which defines
a fluid conduit 98. The boss portion has a distal end 92B which
enters the opening 84 to form the valve inlet. The boss portion has
a raised half toroid surface at its distal end that creates a
sealing ring or valve seat 92A. The valve seat is pressed up
against the disk portion 86A to create a seal, with the elasticity
of the membrane biasing the disk portion against the valve seat to
close the valve. When an adequate pressure difference is
experienced across the two sides of the disk portion, the force
created by the pressure gradient forces the disk away from the
inlet, i.e. away from the sealing ring 92. This displacement allows
fluid to flow through the fluid conduit from chamber 94 to chamber
96.
Alternate disk valve arrangements can be employed using the
over-molding technique. For example, disk valve structure 80' is
illustrated in the cross-sectional view of FIG. 10. In this
embodiment, the web portion 86B has through holes 86C formed
therein. The substrate member 90' is positioned in sealing contact
with the lower over-molded layer 86D of the elastomeric material
which forms the membrane structure 88. The valve 80' permits fluid
flow through conduit 98 when the differential fluid pressure lifts
disk portion 86A away from the seat 92A on boss portion 92',
allowing fluid to flow from chamber 94' through openings 86C to
chamber 96'.
The over-molding techniques can be employed to create ganged sets
of valves. An exemplary ganged set 100 of over-molded valve
structures is illustrated in FIGS. 11-12. As shown therein, the set
100 includes a rigid substrate 102 having a plurality of through
holes 106A, 106B, 106C. An elastomeric structure 104 including
layers 104D, 104E, with elastomeric valve portions 104A, 104B, 104C
are over-molded onto the substrate. Each valve portion comprises a
duckbill portion 104A-1, 104B-1, 104C-1, in which a slit 104A-2,
104B-2, 104C-2 is cut or lanced. Each duckbill valve portion
operates in the same manner as described above regarding the valve
structure 20 of FIGS. 1-3. Of course, ganged sets could be also be
employed using the over-molded disk valve geometries of FIGS.
10-12, or assembled using multiple structures 50 as shown in FIGS.
4-7.
The set 100 can be employed in assemblies having multiple fluid
channels and control fluid flow through the different fluid
channels. Multiple valves can be formed in a single process.
It is understood that the above-described embodiments are merely
illustrative of the possible specific embodiments which may
represent principles of the present invention. Other arrangements
may readily be devised in accordance with these principles by those
skilled in the art without departing from the scope and spirit of
the invention.
* * * * *